Orthopedic Locking Screw

ABSTRACT

An orthopedic locking screw arranged in a bore of an orthopedic implant enables easy removal of a broken locking screw out of the implant. The orthopedic locking screw for a cooperation with a thread in the orthopedic implant comprises a longitudinally extending shaft. The shaft comprises a thread pattern section extending at least partially along the shaft. The thread pattern section comprises a first thread with a first direction, which is a functional thread configured for the cooperation with the thread in the orthopedic implant. The thread pattern section further comprises a second thread with a second direction opposite to the first direction of the first thread. The second thread is superimposed on the first thread and intersects the first thread. An orthopedic locking system comprises the orthopedic locking screw and the orthopedic implant. The locking screw is manufactured by applying the thread pattern section to the longitudinally extending shaft.

CROSS-REFERENCE TO RELATED APPLICATIONS

The present application is a continuation of U.S. patent application Ser. No. 16/761,117, filed on May 1, 2020, which is a U.S. national phase entry under 35 U.S.C. § 371 of International Application No. PCT/IB2017/057688, filed on Dec. 6, 2017, the disclosures of which are hereby incorporated by reference herein in their entirety.

FIELD OF INVENTION

The invention relates to an advanced orthopedic locking screw configured to be arranged in a bore of an orthopedic implant, an orthopedic locking system comprising such locking screw and a method for manufacturing such orthopedic locking screw. Particularly, the invention allows a removal of a broken locking screw out of an implant.

BACKGROUND OF THE INVENTION

In orthopedic procedures, it is often necessary to secure an orthopedic implant. In such cases, an orthopedic locking screw of an orthopedic fastening system is often used to secure the orthopedic implant to a bone or to another orthopedic implant. The screw sometimes breaks during installation or use so that a part of the screw remains in a hole into which it was threaded. In some instances, the locking screw may be broken due to excessive loading or accidents, e.g., due to shearing forces, at the fixation interface. Usually, a broken or damaged locking screw needs to be removed from the human body.

Various devices exist to remove such implanted broken screws. Some of these prior art devices have their own screw threads to be attached to the broken screw for reverse turning of the screw for its removal. Those instruments often have a tapered opening at their threads for telescoping with the broken screw to grip it in the removal process. Such devices have the disadvantage of also removing a relatively large core of the bone, resulting in considerable bone loss. Accordingly, there is a need to provide a locking screw, which when broken, can be easily removed essentially without damaging bone tissue.

BRIEF SUMMARY OF THE INVENTION

The problems of the prior art are addressed by the subject matter of the independent claims, wherein further embodiments are incorporated in the dependent claims. Aspects of the invention described in the following apply also to the advanced orthopedic locking screw system and the method for manufacturing the orthopedic locking screw.

According to an aspect of the present invention, an orthopedic locking screw is presented. The orthopedic locking screw is configured for a cooperation with a thread in an orthopedic implant and comprises a longitudinally extending shaft. The longitudinally extending shaft comprises a thread pattern section extending at least partially along the shaft. The thread pattern section comprises a first thread with a first direction, in which the first thread is a functional thread configured for the cooperation with the thread in the orthopedic implant. The thread pattern section further comprises a second thread with a second direction opposite to the first direction the first thread. The second thread is superimposed on the first thread and intersects the first thread.

The orthopedic locking screw may be an angular stable locking screw and may be provided to secure the orthopedic implant. The orthopedic locking screw may fasten the orthopedic implant precisely without additional components through a bore of the implant. The bore may be arranged with an internal thread to cooperate with the thread pattern section of the locking screw.

The functional thread of the locking screw may interact with the internal thread of the orthopedic implant. However, when the locking screw fatigues, it usually bends and breaks within the implant itself. The functional thread of the thread pattern section may then also allow for removal of a retained portion of the screw without damaging the adjacent bone tissue. In other words, the thread pattern section may allow an interaction between the thread turns of the functional thread of the locking screw and the internal thread of the orthopedic implant and, at the same time, allow for an easily removal of the retained broken screw from the implant in case of a failure of the screw.

The first thread of the thread pattern section might be screwed in the bore of the implant to fasten it. The second thread of the thread pattern section might be a counter screw thread in opposite direction to the first thread such that the second thread and the first thread intersect each other in the thread pattern section. The term “intersect” means that second thread turns overlap first thread turns and vice versa. Accordingly, each thread intervenes, interrupts and/or interferes a counter thread flow. Accordingly, the second thread turns interrupt the first thread flow and vice versa. In other words, the first thread turns are cut by the passing second thread turns and vice versa. The first and second threads may thereby form at least one island, and preferably a plurality of intersection islands, along the circumference of the thread pattern section. Each intersection island may resemble a roller of a music box. The thread pattern section can also be understood as a groove and intersection island system.

In an example, the thread pattern section may comprise essentially rhombic protrusions and multiple grooves between the rhombic protrusions. By intersecting the first thread and second thread, crossing crests of the first and second threads and crossing roots of the first and second threads may form grooves. If crossing crests of the first thread meet crossing roots of the second thread or crossing roots of the first thread meet crossing crests of the second thread, an intersecting area may form a rhombic protrusion due to a helical structure of the threads. Accordingly, a strong internal cooperation of the first thread of the locking screw and the internal thread of the implant can be realized. At the same time, the thread pattern section may be efficiently sheared off when removing the broken locking screw.

In an example, the functional first thread and the superimposed second thread of the thread pattern section may have the same pitch. Hence, grooves and rhombic protrusions in the thread pattern section may have identical size and shape, which allows an even distribution of the interlocking and shearing-off forces between the first thread of the locking screw and the internal thread of the implant. In another example, the functional first thread and the superimposed second thread of the thread pattern section may have a different pitch.

In an example, the functional thread may be a right hand thread and the superimposed second thread may be a left hand thread. In another example, the functional thread is a left hand thread and the second thread is a right hand thread. Usually the locking screw is turned in the right hand direction when fastened. Hence, any special skills may not be required to operate or even to manufacture the functional thread section of the locking screw.

In an example, the orthopedic locking screw may further comprise a neck thread arranged between the thread pattern section and a screw head of the locking screw. The neck thread may have an identical pitch and direction as the functional first thread. Hence, the neck thread and the functional thread can be continuously formed on the shaft of the locking screw. In another example, the neck thread may have a different pitch and direction as the functional first thread.

In an example, a cross section of the thread pattern section of the orthopedic locking screw within a plane along a central axis defined by the screw may have an initial major diameter. Further, a screw neck area near a screw head may have a neck major diameter, and the neck major diameter may be larger than the initial major diameter. The major diameter of the thread is to be understood as the larger of two extreme diameters delimiting the height of the thread profile, as a cross-sectional view is taken in a plane containing the axis of the threads. For a screw, this is generally its outside diameter. Hence, the neck thread may serve to interlock the locking screw in a cortex of a bone, when the locking screw is fastened in the bone or to the implant. The major diameter from the neck thread to the thread pattern section may be reduced steadily along the longitudinal direction of the shaft or stepwise between the screw head and the thread pattern section.

In an example, the orthopedic locking screw further comprises a tip thread arranged between the thread pattern section and a screw tip. The tip thread may have an identical pitch and direction as the functional first thread. Hence, the tip thread and the functional thread can be continuously formed on the shaft of the locking screw. In another example, the tip thread may have a different pitch and direction as the functional first thread.

As stated above, a cross section of the thread pattern section of the orthopedic locking screw may have an initial major diameter. A screw tip area near the screw tip may have a tip major diameter and the tip major diameter may be smaller than the initial major diameter. Accordingly, the locking screw passing the implant also can be fastened on the opposite side to an insertion location of the locking screw in the bone. The major diameter from the thread pattern section to the tip thread may be reduced steadily along the longitudinal direction of the shaft or stepwise between the thread pattern section and the screw tip.

In an example, the orthopedic locking screw may further comprise a screw head having a (counter) screw thread. The (counter) screw thread may have a direction similar or opposite to the functional thread. In the latter case, the orthopedic locking screw can be held by a screw driver engaged with, and preferably threaded onto, the counter screw thread. The counter screw thread may be arranged outwardly on the screw head in an opposite direction to the fastening direction of the locking screw. For example, when the locking screw is fastened in the orthopedic implant in the right hand direction, the locking screw may be firmly held to the screw driver, because the screw head is screwed in a left hand direction into the screw driver. As a result, it may not be necessary to hold the screw with a second hand.

In an example, the second thread intersecting the functional first thread may configure thread turns of the functional first thread for an override of the normal operation of the first thread when forcefully removing the screw out of the implant. The functional thread of the thread pattern section configured for an override of its thread turns may allow for removal of a retained portion of the screw without damaging the adjacent bone tissue. In other words, the locking screw may interact with the internal thread of the orthopedic implant by means of its functional thread configured for an override of its thread turns. The term “configured for an override” may be understood in that the thread turns of the functional thread of the locking screw may be reduced to allow a shearing off and thereby a striking or hammering of the screw throughout the implant to remove the locking screw when it is broken. A residual shear surface of the thread turns may be still sufficient to allow an interaction between the thread turns of the functional thread of the locking screw and the internal thread of the orthopedic implant.

In an example, the second thread intersecting the functional first thread may configure a shearing area of the thread turns of the functional first thread for an intended shearing-off when forcefully removing the orthopedic locking screw in case of a failure of the locking screw. The shearing area may be arranged on a proximal portion of the shaft of the locking screw, may extend in a longitudinal direction of the screw and may serve as a main contact surface of the locking screw to interlock with the internal thread in the bore of the orthopedic implant. As a result, the shearing area of the functional thread allows a locking in the bore of the implant between the internal thread of the implant and the functional thread of the screw and to be easily sheared off in case the broken locking screw has to be extracted.

In an example, the orthopedic implant is an intramedullary nail and the functional thread of the thread pattern section is configured for a cooperation with an inner thread of a bore of the intramedullary nail. Since a breakage of the orthopedic locking screw often occurs in such an intramedullary nail, it is in this case particularly advantageous if the screw can be easily removed.

In an example, the shaft of the orthopedic locking screw may comprise a cannulation.

According to the present invention, also an orthopedic locking system is presented. The orthopedic locking system comprises above described orthopedic locking screw and an orthopedic implant. The orthopedic locking screw is configured for a cooperation with a thread in the orthopedic implant. The orthopedic locking screw may allow a stable transverse locking at a distal end of the orthopedic implant.

According to another aspect of the present invention, a manufacturing method for an orthopedic locking screw is presented. It comprises the following steps:

-   -   applying a first thread of a thread pattern section onto a         longitudinally extending shaft with a first direction, the first         thread being a functional thread configured for the cooperation         with the thread of the orthopedic implant, and     -   applying a second thread of the thread pattern section onto the         longitudinally extending shaft with a second direction opposite         to the first direction of the first thread. The second thread is         superimposed on the first thread and at least partially         intersects the first thread.

The thread pattern section may comprise grooves between essentially rhombic protrusions. The functional first thread and the superimposed second thread of the thread pattern section may have the same pitch. The functional thread may be a right hand thread.

It shall be understood that the orthopedic locking screw and the orthopedic locking system according to the independent claims have similar and/or identical preferred embodiments, in particular, as defined in the dependent claims. It shall be understood further that a preferred embodiment of the invention can also be any combination of the dependent claims with the respective independent claim.

These and other aspects of the present invention will become apparent from and be elucidated with reference to the embodiments described hereinafter.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a side cross-sectional view of an orthopedic implant.

FIG. 2a and FIG. 2b are side views of orthopedic locking screws according to embodiments of the present invention.

FIG. 3a is a perspective view of an orthopedic locking screw before forming a thread.

FIG. 3b is a perspective view of the orthopedic locking screw of FIG. 3a with a left hand thread.

FIG. 3c is a perspective view of the orthopedic locking screw of FIG. 3a with a right hand thread.

FIG. 3d is a perspective view of the orthopedic locking screw of FIG. 3a after applying left and right hand threads.

FIG. 4a and FIG. 4b are side cross-sectional views of an orthopedic locking system according to an embodiment of the present invention.

FIG. 4c is a close up side view of a shaft of the orthopedic locking screw of FIGS. 4a and 4 b.

DETAILED DESCRIPTION

In orthopedic procedures, it is often necessary to secure an orthopedic implant. In such cases, an orthopedic fastening system may be provided in which an orthopedic locking screw secures an orthopedic implant to a bone or to another orthopedic implant.

As shown in FIG. 1, an orthopedic implant 200 generally comprises at least a bore 210 and an internal thread 220 to secure a locking screw (not shown). In some arrangements, the orthopedic implant may be, for example, an intramedullary bone nail, with one or more bores extending partially or completely therethrough for receiving a locking screw therein. The orthopedic implant is not limited to being an intramedullary bone nail. The orthopedic implant may be, for example, a plate or bone connector, or another type of orthopedic implant.

FIGS. 2a and 2b illustrate an orthopedic locking screw 100 according to an embodiment of the present invention. The orthopedic locking screw 100 comprises a shank or shaft 110, a screw head 120 and a screw tip 130. The shaft 110 may have an elongate, form. The shaft 110 may be generally cylindrical, having a substantially constant major diameter extending between the screw head 120 and the screw tip 130. The locking screw 100 may have a region of smaller and tapering diameter at the end near the screw tip.

The screw head 120 at a proximal end of the locking screw 100 comprises a recess 121 and an outer thread 122. The recess 121 is configured to receive a rotational drive, such as a screw driver or wrench. Hence, the orthopedic locking screw 100 may be rotated around a longitudinal axis of the shaft 110 in order to operably engage the orthopedic locking screw 100 with bone 300 (see FIG. 4a ) and/or the implant 200. The recess 121 is not limited to a particular shape. For example, the recess 121 may have a socket adapted to receive a square or hexagonal drive, or a slot for receiving a screw driver. The outer thread 122 of the screw head 120 is configured in an opposite direction to the fastening direction of the locking screw 100 to be held by the screw driver by means of a self-holding mechanism during threading of the locking screw 100 into a mating structure, such as the orthopedic implant 200.

The screw tip 130 extends from the distal end of the shaft 110. The screw tip 130 tapers to a point or, alternatively, to a blunt nose, such as a rounded, flat, or truncated nose. The tip 130 may comprise a self-tapping element 131 for tapping a bore into bone 300. The self-tapping element 131 may comprise at least one, and optionally two or more diametrically opposite axial grooves 132 extending along the tip 130. The axial grooves 132 may be at least partially helical. The axial grooves 132 define an edge that may act to scoop away bone or other material as the orthopedic locking screw 100 is rotated and advanced into the bone 300.

The orthopedic locking screw 100 may be more particularly detailed by a thread pattern section 150, a neck 160 between the head 120 and the thread pattern section 150, and a transition section between the thread pattern section 150 and the tip 130. As shown in FIG. 2a , the head 120 of the locking screw 100 may be configured to have a bigger major diameter than a major diameter of the shaft 110. Further, in one arrangement, one or both of a major diameter of the neck 160 and a major diameter of the transition section 170 may be similar to the major diameter of the thread pattern section 150. In the present embodiment, the major diameter of the neck 160 is larger than the major diameter of the thread pattern section 150, and a major diameter of the tip 130 is smaller than the major diameter of the thread pattern section 150. Hence, the transition section 170 is provided with a taper from the thread pattern section 150 to the distal end of the locking screw, i.e. the tip 130. In this manner, the transition section 170 is used to draw the shaft 110 through the implant bore 220.

FIG. 3a to FIG. 3d show an exemplary manufacturing method of the locking screw according to an embodiment of the present invention. As a first step to shape the thread pattern section 150 of the locking screw 100, a left hand thread 152 is arranged in the thread pattern section 150, as shown by a comparison of FIG. 3a and FIG. 3b . Afterwards, a right hand thread 151 is arranged at least partially, and preferably completely, from the neck 160 to the distal end of the locking screw 100 (comparison between FIG. 3a and FIG. 3c ). Accordingly, the neck portion 160, the transition portion 170 and the tip portion 130 are threaded in the same direction and with the same pitch as the thread pattern section 150. The right hand thread serves as a functional thread 151 configured to cooperate with an internal thread, such as the inner thread 220 of the orthopedic implant 200. Since the left hand thread and the right hand thread intersect each other in the thread pattern section 150, the thread pattern section 150 is constituted of remaining flanks of both threads and grooves 153 between the flanks accordingly. As shown by FIG. 3b and FIG. 3c , the pitch of the left hand thread is larger than the pitch of the right hand thread.

The remaining flanks in the thread pattern section 150 are provided in the form of rhombic protrusions 154. The thread turns of the functional thread 151 in the thread pattern section 150 include a shearing area provided by the rhombic protrusions 154. The thread pattern section 150 is configured for the cooperation with the inner thread 220 of the orthopedic implant 200 and for an intended shearing-off when removing the orthopedic locking screw 100 in a case of a failure of the screw 100.

FIG. 4a and FIG. 4b show an orthopedic locking system using an orthopedic locking screw 100. An orthopedic implant 200 such as an intramedullary nail is inserted in a bone 300 comprising marrow 310. The marrow 310 is circumferentially encased by cortex as illustrated by a first cortex portion 320 and a second cortex portion 330. In a further step, a tip 130 of the locking screw 100 is inserted through the first cortex portion 320 and marrow 310 into a bore 210 of the orthopedic implant 200. A shaft 110 is advanced into the bore 210 in any sufficient manner, such that the tip 130 is advanced through the bore 210. Since the major diameter of the tip 130 is different (e.g., smaller) from the major diameter of a thread pattern section 150, the tip 130 operates to advance (e.g., by pushing) the shaft 110 forward through the bore 210 of the orthopedic implant 200. When the thread pattern section 150 comes into engagement with an internal thread 220 of the bore 210, the shaft 110 may be rotated, for example with a screw driver engaged at a screw head to advance the shaft 110 into and/or through the bore 210. Accordingly, the thread pattern section 150 engages the bore 210 so as to form a mechanical intermeshing fit with the internal thread 220 of the bore 210 as shown in FIG. 4a and FIG. 4b . When the tip 130 comes into contact with the bone 300 on the opposite side of the orthopedic implant 200, i.e., with the second cortex portion 330, the locking screw 100 is rotated further, so as to engage the tip 130 with the bone 300.

In case of a breakage of the locking screw 100 inside the bone 300, a proximal portion of the broken locking screw 100 may be removed by screwing out the screw 100 in the loosening direction using, for example, an appropriate screw driver. Further, a distal portion of the broken screw 100 may be removed by striking it at the broken side of the screw 100 in direction of the second cortex portion 330. The thread pattern section 150 generally cooperates with the internal thread 220 of the orthopedic implant 200 in an engaged state. However, the thread pattern section 150 also allows for overriding of the functional thread turns 151 and instead use of the left hand thread 152 in order to remove the broken screw 100 out of the implant 200. Hence, the broken locking screw 100 can be easily removed without injuring an adjacent bone tissue.

While the invention has been illustrated and described in detail in the drawings and foregoing description, such illustration and description are to be considered illustrative or exemplary and not restrictive. The invention is not limited to the disclosed embodiments. Other variations to the disclosed embodiments can be understood and effected by those skilled in the art in practicing a claimed invention, from a study of the drawings, the disclosure, and the dependent claims.

In the claims, the word “comprising” does not exclude other elements or steps, and the indefinite article “a” or “an” does not exclude a plurality. The mere fact that certain measures are recited in mutually different dependent claims does not indicate that a combination of these measures cannot be used to a further advantage. Any reference signs in the claims should not be construed as limiting the scope. 

1. An orthopedic locking screw comprising: a shaft including a thread pattern section extending along at least part of the shaft, the thread pattern section including a first thread oriented in a first direction and a second thread oriented in a second direction opposite the first direction, the first thread including a helically extending crest and the second thread including a plurality of rhombic shaped crests recessed relative to the helically extending crest.
 2. The orthopedic locking screw of claim 1, wherein the plurality of rhombic shaped crests together define a helical path along part of the shaft.
 3. The orthopedic locking screw of claim 2, wherein the plurality of rhombic shaped crests include at least a first rhombic shaped crest smaller than a second rhombic shaped crest, the first rhombic shaped crest being closer to a tip of the shaft than the second rhombic shaped crest.
 4. The orthopedic locking screw of claim 1, wherein the helically extending crest and each of the plurality of rhombic shaped crests have a first width measured in a direction perpendicular to a longitudinal axis of the first thread.
 5. The orthopedic locking screw of claim 1, wherein the thread pattern section includes a helically extending root adjacent to the helically extending crest, the helically extending root being separated from each of the plurality of rhombic shaped crests by a step.
 6. The orthopedic locking screw of claim 5, wherein the helically extending root does not overlap with the first thread or the second thread.
 7. The orthopedic locking screw of claim 1, further comprising a head abutting an end of the shaft, the head having an outer thread oriented in the same direction as the second thread.
 8. A system comprising: the orthopedic locking screw of claim 1; and an orthopedic implant including a bore with a threaded surface, wherein the first thread of the orthopedic locking screw is functionally engageable with the threaded surface of the bore.
 9. An orthopedic locking screw comprising: a shaft including a thread pattern section over at least part of the shaft, the thread pattern section including a helical crest and a helical root, a first part of the helical crest defining a first thread in a first direction and a second part of the helical crest defining a second thread in a second direction opposite the first direction, the first part being separate from the second part, wherein the helical crest has a first minimum height relative to the helical root at the first part and a second minimum height relative to the helical root at the second part, the first minimum height being greater than the second minimum height, and wherein the second part includes plurality of second subparts, each of the plurality of second subparts including a circumferentially planar surface extending from a leading edge to a trailing edge, the leading edge and the trailing edge both being at an oblique angle relative to a longitudinal axis of the helical crest.
 10. The orthopedic locking screw of claim 9, wherein the first part includes a plurality of first subparts, each of the plurality of first subparts being separated by one of the plurality of second subparts.
 11. The orthopedic locking screw of claim 10, wherein each of the plurality of second subparts has a rhombic shape and each of the plurality of first subparts has a non-rhombic shape.
 12. The orthopedic locking screw of claim 10, wherein each of the plurality of second subparts includes a central region that includes the circumferentially planar surface, the central region being in between sloped regions abutting the first part.
 13. The orthopedic locking screw of claim 9, wherein the second thread defines a helical path in the second direction such that each of the plurality of second subparts is separated by the helical root.
 14. A system comprising: the orthopedic locking screw of claim 9; and an orthopedic implant including a bore with a threaded surface, wherein the first thread of the orthopedic locking screw is functionally engageable with the threaded surface of the bore.
 15. An orthopedic locking screw comprising: a shaft including a thread pattern section over at least part of the shaft, the thread pattern section including a first thread in a first direction and a second thread in a second direction opposite the first direction, the second thread being entirely within the first thread such that the second thread is defined by a plurality of recessed portions in the first thread, wherein the first thread includes a crest centered along a first central longitudinal axis of the first thread, wherein each of the plurality of recessed portions includes a first edge, a second edge and a surface therebetween, the first edge and the second edge being on opposite sides of the first central longitudinal axis of the first thread and the surface being at a substantially uniform distance from a second central longitudinal axis of the shaft, and wherein each of the plurality of recessed portions is asymmetrical about a plane substantially aligned with and passing through the first central longitudinal axis and the shaft.
 16. The orthopedic locking screw of claim 15, wherein each of the plurality of recessed portions has a first surface area on a first side of the first central longitudinal axis and a second surface area on a second side of the first central longitudinal axis, the first surface area being equal to the second surface area.
 17. The orthopedic locking screw of claim 15, wherein the first edge and the second edge are adjacent to a root of the thread pattern section.
 18. The orthopedic locking screw of claim 15, wherein each of the plurality of recessed portions extend a first maximum distance on a first side of the first central longitudinal axis and the first maximum distance on a second side of the first central longitudinal axis.
 19. The orthopedic locking screw of claim 15, wherein each of the plurality of recessed portions has a shape with an axis of symmetry passing therethrough, the axis of symmetry being at an angle relative to the plane.
 20. A system comprising: the orthopedic locking screw of claim 15; and an orthopedic implant including a bore with a threaded surface, wherein the first thread of the orthopedic locking screw is functionally engageable with the threaded surface of the bore. 